EP3017525B1 - Arrangement of electrical actuators and method of manufacturing a motor included in an actuator belonging to such an arrangement - Google Patents

Description

The present invention relates to a range of electric actuators and a method of manufacturing a motor included in an actuator belonging to such a range.

The electric actuators considered are actuators of movable closing elements, occultation or sun protection such as a shutter, a door, a grid, a blind, or any other equivalent equipment, hereinafter called screen.

The screens fitted to the buildings have various dimensions and the choice of materials used has a considerable impact on the mass and inertia of the moving parts and, consequently, on the torque required for the operation of the latter.

Manufacturers of motors and actuators for the automatic operation of such screens are generally faced with the need to provide a range of actuators with different torque characteristics, dimensions or different power supplies, in order to be in line with the characteristics of the screens or installations comprising these screens.

The invention relates in particular to so-called "tubular" actuators used in home automation applications. Engines generally used in this type of actuators are asynchronous motors, which can be powered directly from the AC mains. Other motors used are DC motors, with brushes and collectors, which are fed from the AC network by means of a continuous AC converter or directly from an energy storage device, such as 'a battery. Alternatively, electronically commutated brushless electric motors are regularly used in other applications, such as pumps, fans or electrical tools.

The tubular actuators have an elongate casing to be threaded into a winding tube on which the door or the shutter is wound in order to release an access (passage door, window). The motors included in such actuators are therefore designed to have a diameter limited in relation to their length. To increase the torque produced by the actuator, it is known to provide a larger actuator diameter. The motor can thus have a larger output torque, which goes hand in hand with the increase in the winding diameter of the screen. In this field of electric motors and actuators, it is therefore known, for example from the document US-A1-2006 / 273686 to use, according to the torque to be delivered, engines of similar construction but whose diameters are different. That is to say that, depending on the torque to be delivered, a given actuator will not include the same stator or the same rotor as another actuator. This results in a cost of multiple reference management for the manufacturer and a dispersion of production volumes increasing the unit price of the parts used, that is to say, rotors and stators and more generally engines and actuators.

In addition, it is known that depending on the type of electric motor desired, that is to say a synchronous or asynchronous or DC motor, the components used for their manufacture, that is to say the stators, rotors used for construction, are different. It also results in a cost of multiple reference management and a dispersion of production volumes.

It is these drawbacks that the invention intends to remedy by proposing a range of actuators whose manufacturing costs as regards their electric motor are reduced.

For this purpose, the invention relates to a range of at least two actuators according to claim 1.

Thanks to the invention, the first and the second actuators use the same central core which makes it possible to produce two different motors comprising an identical central core forming either a stator or a rotor. This therefore reduces the manufacturing costs of the actuators and reduce the number of references for the manufacturer. For example, it is possible to construct a first actuator whose diameter is such that it can be inserted into a winding tube of diameter, for example equal to 50 mm, which includes the same stator as that used for the construction of a second actuator which delivers a higher torque than that delivered by the first motor. The second actuator makes it possible, for example, to motorize a shutter whose diameter of the tube on which it is wound is larger, that is to say for example equal to 60 mm.

According to advantageous but not obligatory aspects of the invention, such an electric motor may incorporate one or more of the optional features of claims 2 to 9.

The invention also relates to a method of manufacturing a motor of an actuator according to claim 10.

• la figure 1 est une représentation schématique d'une gamme d'actionneurs conforme à l'invention ;
• la figure 2 est une coupe axiale d'un moteur inclus dans un premier actionneur de la figure 1 ;
• la figure 3 est une coupe axiale d'un moteur inclus dans un deuxième actionneur de la figure 1 ;
• la figure 4 est une coupe axiale d'un moteur inclus dans un troisième actionneur de la figure 1 ;

The invention will be better understood and other advantages thereof will appear more clearly in the light of the following description of a range of at least two actuators and a method for manufacturing an engine included in FIG. an actuator belonging to such a range, given only by way of example and with reference to the accompanying drawings in which:

• the figure 1 is a schematic representation of a range of actuators according to the invention;
• the figure 2 is an axial section of a motor included in a first actuator of the figure 1 ;
• the figure 3 is an axial section of a motor included in a second actuator of the figure 1 ;
• the figure 4 is an axial section of a motor included in a third actuator of the figure 1 ;

To the figure 1 a range 100 which includes a first 1a, a second 1b, a third 1c and a fourth 1d tubular actuators is shown. These actuators 1a, 1b, 1c and 1d are powered by the sector represented by the phase P and neutral N wires. They make it possible to actuate a shutter 2a, 2b, 2c, 2d.

As a variant, the shutter 2a, 2b, 2c, 2d is more generally a movable closing, occulting or sun protection screen, wound on a winding tube, not shown, whose inside diameter is substantially equivalent to external diameter of the actuator, so that the actuator can be inserted into the tube. Alternatively, the actuator is intended to be placed in a U-shaped rail.

The actuators 1a, 1b, 1c and 1d respectively comprise first, second, third, fourth electric motors 4a, 4b, 4c, 4d, which are different from each other. The first and second motors 4a, 4b are in particular of DC brushless direct current type, the third motor 4c is DC type, while the fourth 4d motor is asynchronous type.

The actuators 1a, 1b, 1c each comprise a first, second, third continuous AC converter 3a, 3b, 3c. Continuous AC converters 3a, 3b, 3c have the same electronic structure, the sizing of certain components being different. The converters 3a, 3b and 3c are for example of the switching type (pulse width modulation). In a variant, the converters 3a, 3b and 3c are of the transformer and rectifier type.

The converters 3a, 3b, 3c each comprise a rectifying device 5a, 5b, 5c of the mains voltage, a capacitor 6a, 6b, 6c, a transistor 7a, 7b, 7c and a control circuit 8a, 8b, 8c, which are adapted to the power range deliverable by the motor 4a, 4b, 4c. For each first, second, third actuator 1a, 1b, 1c, the mains voltage is rectified by the rectifying device 5a, 5b, 5c corresponding and is used to charge the corresponding capacitor 6a, 6b, 6c disposed between the output terminals of the converter 3a, 3b, 3c corresponding. The charge of the capacitor 6a, 6b, 6c is controlled by the transistor 7a, 7b, 7c which is controlled by the control circuit 8a, 8b, 8c.

The fourth actuator 1d comprises a relay 8d for driving the fourth motor 4d connected, on the one hand, to the phase P and to the neutral N and, on the other hand, to the fourth motor 4d.

The first, second and third motors 4a, 4b and 4c respectively corresponding to the three actuators 1a, 1b and 1c are respectively represented in FIGS. figures 2 , 3 and 4 .

The first engine 4a, shown alone at figure 2 , comprises a rotor 10 and a stator 12.

The rotor 10 comprises a rotor body 15, which is surrounded by the stator 12. This rotor 10 also comprises a rotor shaft 14, on which the rotor body 15 is fixed. The rotor 10 and the stator 12 are arranged so coaxial around a geometric axis X14. The rotor body 15 is integrally connected in rotation to the shaft 14, which is centered on the axis X 14 and protrudes on either side of the body 15. Thus, the rotor shaft 14 comprises a first 14a and a second 14b projecting ends of the rotor body 15.

For convenience, the following description of the motors 4a, 4b, 4c and 4d is oriented relative to the axis X14, considering that the terms "inner" and "internal" qualify a portion of the engine 4a, 4b, 4c or 4d which is directed transversely to the axis X14, while the terms "outside" and "external" correspond to a transverse direction of opposite direction.

The rotor body 15 is generally formed from a sheet stack or solid shaft and on the outer circumference of the rotor body 15 a permanent magnet 16 is positioned. The permanent magnet 16 surrounds the body 15. The magnet 16 is separated from the stator 12 by an air gap 18. The permanent magnet 16 consists either of a polarized annular magnet as shown in FIG. figure 2 or several separate magnets, reported on the outer circumference of the rotor body by gluing, overmolding or any other known technique. The permanent magnet 16 more generally corresponds to magnetic elements 16 positioned on the outer circumference of the rotor body 15.

The stator 12 defines an internal annular space E in which the rotor 10, and in particular the permanent magnet 16, is positioned and inside which the rotor 10 is rotated when the motor 4a is operating.

The diameter D1 of the annular space E is such that this space E receives the rotor 10 as well as the permanent magnet 16. The magnetic (or magnetized) part of the rotor 10 located inside the internal annular space E at the stator 12, the rotor 10 is called internal rotor.

The annular space E also receives a first bearing 20 and a second bearing 22 of rotation of the shaft 14. Indeed, the rotor shaft 14 is supported at both ends 14a and 14b via the two bearings 20 and 22. More specifically, the first end 14a of the shaft 14 is in contact with the first bearing 20 while the second end 14b of the shaft 14 is in contact with the second bearing 22. The bearings 20 and 22 are, for example, ball bearings. The first 20 and second 22 bearings are thus positioned on either side of the rotor body 15, parallel to the axis X14.

A central core 24 is here formed by the stator core 24 belonging to the stator 12. The stator core 24 is made of magnetizable material and more specifically ferromagnetic material, and is generally formed by a stack of sheets and provided with insulating gaskets.

The stator core 24 comprises polar elements 26, distributed on the outer periphery of the stator 12 and protruding outwards. Windings 28 are positioned around the pole elements 26 of the stator 12 generally parallel to the axis X14. More specifically, each polar element 26 is surrounded by a winding 28 which is specific to it. The coils 28 are connected so that when they are traversed by a current, they produce a rotating magnetic field which drives the rotor 10. The coils 28 are isolated from the stator core 24. Like the stator 12, the central core 24 defines the annular space E of diameter D1.

The stator 12, that is to say the central core 24, comprises on its outer circumference a yoke 29. The yoke 29 surrounds the stator 12, that is to say the central core 24, which is specific to the receive, and is centered on the X14 axis. This yoke 29 allows the circulation of the magnetic flux.

The second motor 4b of the second actuator 1b, shown in FIG. figure 3 , comprises a stator which is identical to the stator 12 of the first motor 4a, so that on the figure 3 the stator is pointed by the same reference 12. More precisely, the motor 4b comprises a central core which is identical to the stator core 24 of the first motor 4a, so that on the figure 3 , the central core is pointed by the same reference 24. In addition, the windings of the stator 12 of the second motor 4b are identical to the windings 28 of the stator 12 of the first motor 4a and therefore bear the same reference.

The motor 4b also comprises rotation bearings 29a and 29b which are preferably identical to the bearings 20, 22 shown for the first motor 4a. In a variant, the bearings 29a, 29b are different from the bearings 20, 22 of the first motor 4a.

The motor 4b comprises, unlike the motor 4a, a rotor 30 which comprises a rotor shaft 31 centered on the axis X14 and a rotor body 32 positioned coaxially with the stator 12 around the axis X14, surrounding the stator 12.

More specifically, the rotor 30 is a bell rotor, that is to say it surrounds the stator 12, comprises the rotor shaft 31 at its center and its body 32 has a generally cylindrical shape with an internal diameter D2 greater than the outer diameter D3 of the stator 12. In addition, the structure of the rotor 30 is such that, along the axis X14, on one side of the stator 12, the rotor 30 and more specifically the rotor body 32 comprises a discoidal base 32a. closing and, on the other side, the rotor body 32 is open. The rotor body 32 comprises, on an inner face S1, facing the pole elements 26 of the stator 12, a permanent magnet 33. The permanent magnet 33 is constituted either of a polarized annular magnet as shown in FIG. figure 3 or several separate magnets, reported on the outer circumference of the rotor body by gluing, overmolding or any other known technique. The permanent magnet 33 surrounds the stator 12 and is centered on the axis X14. In addition, the radial dimension of the magnet 33 and the internal diameter D2 of the rotor body 32 are such that an air gap 34 exists between the magnet 33 and the outside of the stator 12, so that the rotor 30 is qualified. external rotor.

The permanent magnet 33 allows rotation of the rotor 30 when the current flowing through the coils 28 creates a magnetic field. The permanent magnet 33 more generally corresponds to magnetic elements 33 which surround the stator 12 and are positioned on the internal face S1.

The rotor 30 is itself made by stacking sheets, in particular the bell of the rotor serves as a cylinder head for the looping of the magnetic flux. It is also possible to bring an external cylinder head if necessary.

In addition, the stator 12, that is to say the central core 24 comprises, in its inner annular space E, a yoke 38. The yoke 38 surrounds the shaft 31 and is centered on the axis X14. It fills the internal space E. An inner face S3 of the central core 24, facing the shaft 31, is adapted to receive the cylinder head 38. The cylinder head 38 is made of ferromagnetic material and runs on the circumference of the inner face. S3. The yoke 38 has a laminated structure, that is to say it is formed from a stack of sheets. Alternatively, it is massive.

The yoke 38 allows the looping of the magnetic flux and also increases the performance of the engine 4b.

The motor 4c of the third actuator 1c, shown in FIG. figure 4 , comprises a rotor 42 formed by a central core which is identical to the stator core 24 of the first motor 4a, so that on the figure 4 , the central core is pointed by the same reference 24. The central core 24 is centered on and positioned around the axis X14.

The central core 24 comprises polar elements identical to the polar elements 26 of the first and second motors 4a, 4b and pointed by the same reference 26.

The polar elements 26 are surrounded by coils 43 parallel to the central axis X14. Each winding 43 is electrically connected to a collector 44 fixed on an outer face of the central core 24, that is to say the rotor 42. Each collector 44 is said to be rotating, and able to rotate in a manner analogous to the second rotor 42 and to power the coils 43.

Thus, because of its structure supporting windings 43, the rotor 42 is said wound rotor.

The rotor 42 comprises a rotor shaft 45 centered on the axis X14 and a rotor body 46 formed by the central core 24 and a yoke 48. The rotor 42 forms, like the stator 12 of the first motor 4a, a first internal annular space, similar to the inner annular space E of the first motor 4a and bearing the same reference E. The first internal annular space E is adapted to receive the yoke 48 which surrounds the rotor shaft 45. More specifically, an internal face similar to the internal face S3 of the central core 24 of the second motor 4b and bearing the same reference S3, is opposite the shaft 45 and is adapted to receive the yoke 48. The yoke 48 is made of ferromagnetic material and runs on the circumference of the face internal S3. The yoke 48 has a laminated structure, that is to say it is formed from a stack of sheets. Alternatively, it is massive. The yoke 48 is mechanically connected in rotation to the shaft 45 and improves the performance of the engine 4c, by increasing the looping of the magnetic flux.

The motor 4c comprises rotational bearings 50a, 50b of larger size than the bearings 20, 22 shown for the first motor 4a.

The motor 4c comprises a stator 52 different from the stator 12 of the first motor 4a. The stator 52 defines a second internal annular space E 'in which the rotor 42 is positioned and inside which the rotor 42 is rotated when the motor 4c operates. The rotor 42 and the stator 52 are positioned coaxially around the central axis X14. The second rotor 42 is thus provided with the yoke 48, the coils 43 and the central core 24 which correspond to magnetic elements surrounded by the second stator 52.

The diameter D4 of the second annular space E 'is such that this space E' receives the rotor 42 and a permanent magnet 54 fixed on an inner face of the stator 52. The diameter D4 of the second annular space E 'is greater than the diameter D1 the annular space E of the stator 12, that is to say the central core 24.

The magnetic part (or magnetized) of the rotor 42 located inside the second internal annular space E 'of the stator 52, the rotor 42 is called internal rotor. In addition, since it supports the windings 43, the rotor 42 is called internal wound rotor.

The stator 52 is formed by a stator core 55 of magnetizable material and more specifically of ferromagnetic material. The stator core 55 is generally formed by a stack of sheets.

The stator 52 comprises brushes 56 facing the collectors 44, able to transmit a current, delivered by a power supply 58, to the collectors 44 and by electrical connection to the coils 43.

The motor 4d of the fourth actuator 1d has a structure generally similar to the engine 4a of the figure 1 . However, the motor 4d comprises a rotor different from the first motor 4a. More specifically, the rotor of the fourth motor 4d comprises, on its outer circumference, a permanent magnet, as shown in FIG. figure 1 , or windings.

Thus, the rotor of the fourth motor 4d is provided with either the aforementioned magnet or the aforementioned windings which correspond to magnetic elements.

Furthermore, the motor 4d comprises an outer shape stator substantially similar to the stator 12 of the first motor 4a (as shown figure 2 ), with polar elements similar to the polar elements 26 of the stator 12. In the fourth motor 4d, the polar elements comprise coils in common, that is to say that the same winding surrounds several polar elements, so as to that the motor 4d is of asynchronous type. However, in the first motor 4a, a winding 28 is adapted to and surrounds only one polar element 26. In a manner similar to that which has been presented for the figure 2 , the stator 12 of the motor 4d comprises on its outer periphery a yoke which surrounds the stator 12.

The stator of the fourth motor 4d surrounds the magnetic elements belonging to the rotor of the fourth motor 4d.

In view of the explanations provided so far, it is understood that the internal annular space E of the central core 24 is adapted to indifferently receive the inner rotor 10 or the yoke 38, or the yoke 48 according to which the stator is arranged respectively in the first motor 4a or the second motor 4b or the third motor 4c.

Thus, in order to construct the first actuator 1a and more specifically the first motor 4a, there is provided the stator core 24 forming the stator 12 which is wound, with a coil 28 for each polar element 26, and the inner rotor 10: the rotor 10 is assembled with the stator core 24, that is to say that the rotor 10, provided with the magnet 16, is positioned in the inner annular space E as well as the bearings 20 and 22. In addition, the yoke 29 is positioned around the stator 12.

To manufacture the second actuator 1b and more specifically the motor 4b, the central core 24 forming the stator 12 and the outer rotor 30 is provided: the outer rotor 30 is assembled with the central core 24, that is to say that the outer rotor 30, provided with the magnet 33, and the central core 24, and the bearings 29a and 29b, are assembled coaxially along the axis X14. In addition, before positioning the bearings 29a and 29b, the yoke 38 is fixed on the inner surface S3.

Insofar as an external rotor motor provides a greater torque than an internal rotor motor, all other things being equal, especially when these two motors comprise the same stator, during the manufacture of one of the engines 4a and 4b, there is a single central core 24 forming the stator 12, an inner rotor 10 and an outer rotor 30, and then the central core 24 is assembled with either the inner rotor 10 or the outer rotor 30 next the couple that the engine to build must deliver.

To manufacture the third actuator 1c and more specifically the motor 4c, the central core 24 forming the rotor 42 and the stator 52 are provided: the central core 24 is assembled with the stator 52, that is to say that the central core 24 provided with the yoke 48 and the coils 43 connected to the collectors 44 is positioned in the second internal annular space E ', the collectors 44 being opposite the brushes 56.

Knowing that the rotor 42 has a greater diameter than the rotor 10 since it is formed of the central core 24 which is adapted to receive the rotor 10 and the diameter D4 of the space E 'is greater than the diameter D1 of the space E, the third motor 4c is able to provide a larger torque than the first motor 4a. Thus during the manufacture of one of the motors 4a and 4c, there is a single central core 24, an internal rotor 10 and a stator 52, then the central core 24 is assembled with either the rotor 10 or the stator 52 depending on the torque that the engine to be built must deliver.

To manufacture the fourth actuator 1d and more specifically the fourth motor 4d, there is the central core 24 and a rotor different from the rotor 10: the central core 24 is then wound differently from the first motor 4a. Indeed, the central core 24 is wound so that several polar elements are surrounded by the same winding.

During the manufacture of one of the motors 4a and 4d, there is a single central core 24, an inner rotor 10 and another rotor different from the rotor 10: then the polar elements 26 of the central core are wound up 24 so that each polar element 26 is surrounded by a winding 28 which is specific to it, and the central core 24 is assembled with the internal rotor 10, to have an electronically commutated DC brushless motor, or on a coil the polar elements 26 of the central core so that at least one winding surrounds several polar elements 26, and assembles the central core 24 with the inner rotor 10, to have an asynchronous motor.

The fact of using the same central core 24 for the range of actuators 100 which deliver different torque values and comprises different types of motors makes it possible to reduce the management and manufacturing costs and to extend a range of actuators, using the same type of central core 24 for applications requiring different types of motors or different torques, in particular for motorization applications of shutters or doors of different sizes and / or weights, or even for other types of applications (eg commercial grids) ..

According to another variant not shown, the motors 4a, 4b, 4c and 4d comprise only one rotation bearing.

Claims (10)

1. Arrangement (100) of at least two actuators (1a; 1b; 1c; 1d) comprising:

   - a first actuator (1a) which includes a first motor (4a) which supplies a first torque, which first motor comprises a first rotor (10) and a first stator (12) which are positioned coaxially about a first axis (X14), the first rotor (10) comprising a first rotor body (15) fitted with magnetic elements (16) which are surrounded by the first stator (12), the first stator (12) being formed by a stator core (24) comprising first polar elements (26) which are distributed over the external periphery of the first stator (12) and project towards the exterior

   - a second actuator (1b; 1c; 1d) which includes a second motor (4b; 4c; 4d), which second motor (4b; 4c; 4d) comprises a second rotor (30; 42) and a second stator (12; 52), the second rotor (30; 42) and the second stator (12; 52) being positioned coaxially about a second axis (X14), the second motor (4b; 4c; 4d) comprising a central core (24) which is identical to said stator core (24) which forms either the second rotor (30; 42) or the second stator (12; 52) and which comprises second polar elements (26) which are distributed over the external periphery of the second rotor (30; 42) or of the second stator (12; 52) and project towards the exterior, one of the second rotor (30; 42) and stator (12; 52) being different respectively from the first rotor (10) and stator (12).
2. Arrangement according to claim 1, characterised in that the first rotor (10) comprises a first rotor shaft (14) which is connected in rotation to the first rotor body (15) by being centred on the first axis (X14), and in that the second rotor, termed external (30), comprises a second rotor body (32) which is fitted with magnetic elements (33) and surrounds the second stator (12), and a second rotor shaft (31) which is connected in rotation to the second rotor body (32) by being centred on the second axis (X14), the central core (24) forming the second stator (12) such that the second motor (4b) is a motor with an external rotor.
3. Arrangement according to claim 1, characterised in that the second rotor (42) is fitted with magnetic elements (42, 43, 48) which are surrounded by the second stator (52) by being centred on the second axis (X14), the central core (24) forming the second rotor (42), and in that the second polar elements (26) are surrounded by windings (43) which are globally parallel to the second axis (X14) such that the second motor (4c) is a motor with a wound rotor.
4. Arrangement according to claim 1, characterised in that each first polar element (26) is surrounded by at least one first winding (58) which belongs to each polar element (26), parallel to the first axis (X14), the first motor (4a) being a brushless motor with direct current by electronic commutation, in that the second rotor is fitted with magnetic elements which are surrounded by the second stator, the central core (24) forming the second stator, and in that several second polar elements are surrounded by an identical second winding, such that the second motor (4d) is an asynchronous motor.
5. Arrangement according to one of the preceding claims, characterised in that the first motor (4a) comprises a first yoke (29) which is centred on the first axis (X14), which is fitted over the external periphery of the first stator (12) and which surrounds the first stator (12).
6. Arrangement according to claim 2 or 3, characterised in that the second motor comprises a second yoke (38; 48) which is received on an internal face (S3) of the central core (24),which is centred on the second axis (X14) and which surrounds the second rotor shaft (31; 45), and in that the central core (24) delimits a first internal annular space (E) about the first axis (X14) and about the second axis (X14), which is able to receive either the internal rotor (10) or the second yoke (38; 48).
7. Arrangement according to claim 4, characterised in that the second motor (4d) comprises a third yoke which is centred on the second axis (X14) and which is fitted over the external periphery of the second stator (12 and which surrounds the second stator (12).
8. Arrangement according to claim 3, characterised in that each winding (43) is connected electrically to a collector (44), termed rotating, which is fixed on the second rotor and able to rotate analogously to the second rotor (42) thus supplying the windings (43) with current with the aid of brushes (56) which are positioned opposite each collector (44) and fixed to the second stator (52).
9. Arrangement according to claims 3 and 6, characterised in that the second stator (52) forms an internal annular space (E'), a first diameter (D4) of which is greater than a second diameter (D1) of the first internal annular space (E).
10. Method of manufacturing a motor (4a; 4b, 4c, 4d) of an actuator (1a, 1b, 1c, 1d) in which there is arranged a single central core (24), a first rotor (10) and a second stator (52) or a second rotor (30),
    characterised in that the central core is:

    - either associated with the first rotor (10) in order to form a first motor (4a) comprising the first rotor (10) and a first stator (12) which is formed by the central core,

    - or associated with the second rotor (30) or the second stator (52), in order to form a second motor (4b; 4c; 4d) which is different from the first motor and comprises either the second rotor (30) and a stator (12) which is formed by the central core (24), or the second stator (52) and a rotor (42) which is formed by the central core (24), according to the torque to be supplied and the type of motor which is desired.

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